1980 gs1000g

[BluePlateSpecial]

Af for the money, its probably cheaper to buy a decent runner than to fix up an unknown non-runner.

Unfortunately vintage bikes are pricey in FL. The only reason I pulled the trigger on this one not knowing whether or not it would run is because I got it for cheap, so worst case is if the engine was unrepairable it's still worth several times what I paid in parts. Hopefully I can get it running though. The more I read about it the more I think it's going to be a great bike.

 

[BluePlateSpecial]

Bumping to see if anyone has some suggestions. Questions in red-

Does anyone know the specs for the screws and washers that hold the cover on the front master cylinder? I can get OEM but I'd like to save a few $$ picking them up locally if possible.

Also, I need some new fork seals. Anything wrong with the $10 generic seals from ebay? Do I need anything other than the seals themselves?

I think I am going to keep the ugly headlight and pick up a viper cafe fairing. Saw a couple of black GS's & KZ's with the fairing and they look sweet. Any problems mounting one of these to what I am working with?

Thanks!

 

[Agemax]

Bumping to see if anyone has some suggestions. Questions in red-

i dont know the size of the screws you need but if you have an old one you could take it with you and get them to match it up.

as for fork seals, they should be OK, dont forget you will also need some fork oil..

 

[BluePlateSpecial]

i dont know the size of the screws you need but if you have an old one you could take it with you and get them to match it up.

as for fork seals, they should be OK, dont forget you will also need some fork oil..

Thanks. For some reason it is missing all 4 screws

 

[Agemax]

Thanks. For some reason it is missing all 4 screws

if the M/C is not all ready fitted and filled with brake fluid then take the M/C to the shop to match up the bolts.

just did a quick search for you. this ebay ad......

http://www.ebay.com.au/itm/Suzuki-G...rcycles_Parts_Accessories&hash=item48443fbf2a

reveals the screws are 4 x 45mm

 

[Steel Toed Tank]

I went with Pyramid brand seals off ebay and while they still hold up well enough one started leaking a little after 3500 kms.

I'm getting OEM ones to replace these, not really happy with them.

 

[BluePlateSpecial]

Heh....I searched ebay, but only for the screws. Didn't even think the sizes might be listed in a rebuild kit.

I picked up the cheap fork seals. I don't ride much, but if I do have a problem I guess I'll fork out the cash for the OEM seals down the road.

Carbs arrived yesterday and look to be in good shape. Sending them over to my guy for cleaning/jetting/rebuild sometime in the next few days. Ordered all of the other parts as well so I should have most of what I need by next week.

 

[BluePlateSpecial]

UPDATE!

I think I might actually get to hear this thing run soon.

Replaced the leaky fork seals and stripped the nasty paint off the lower tubes. 12 hours of sanding and polishing and they are good to go. Swapped the front rim out for the tubeless rim on the parts bike and replaced the front tire. In the process of repainting and rebuilding all brake calipers and I am thinking about ordering some stainless steel brake lines.

It turns out the engine needs rings so we pulled the whole thing and replaced it with the one from my parts bike. That one tested good all the way around and leaks a lot less oil. Replaced the valve cover gasket and the propeller boot when we swapped the engines.

Just got my pods the other day and the rest of the brake parts should be here tomorrow. Special thanks to gsrick for loaning me some jets to help get the carbs dialed in. We are in the process of determining what parts are missing from the carbs and I need to pick up a battery but hopefully I'm done spending money.

Still have to sort out some hacked up wiring and the front master cylinder needs some attention but with any luck I think I might have this thing on the road by the end of next month.

What do you think about gold calipers? The bike is black and the emblems are gold, see pic at the beginning of this thread.

 

[BluePlateSpecial]

I have had this bike for almost a year now and the other day I was FINALLY able to hear it run. Still needs some tuning but it was nice to hear it crank up for a few minutes after all this time.

Special thanks to gsrick for lending me some jets and mario for assembling the carbs.

And now without further adieu, here is what I have been working on off and on for the past 10 months.....

Polished up the forks-


Ooops...missed trying to drill out a frozen screw-


No big deal cause it went through the outside AND I ended up swapping engines anyway-


Cleaning up the valve cover-


Pulled the engine from the parts bike-


1981 GS1000GL parts bike skeleton-


Picture of my "chickenhawk" and my buddy/mechanic Matt's bikes the day we swapped engines-


Two engines, the one that was in the bike is going to need rings, hence the swap-


Matt behind the beast just before we installed the new engine-


Parts bike frame completely stripped down-

 

[BluePlateSpecial]

Bike night! For some reason our vintage club attracts a lot of the newer triumphs and ducatis.....-


Looks like I need some new brake pistons-


Calipers all got a fresh coat of gold paint and the front got rebuild kits-


Just make sure you don't sit the newly painted calipers on a paper towel that is soaked with acetone-


Time to dress up the new helmet with some variegated gold flake-

 

[BluePlateSpecial]

Still needs some pinstriping but otherwise done-


The chickehawk on the day of a charity ride last month-


Crusty master cylinder-


With a big glob of sludge on the inside-


Carbs and pods are on-

 

[BluePlateSpecial]

Deciphering some chopped up wiring-


Master cylinder with spiffy new paint-




Repairing some chopped up wiring by the battery-


Gauges cleaned up and reinstalled-


Still have plenty of sanding and polishing to do-


What do you do with an ugly vetter headlight on a budget build? Plasti dip, of course-




I will try to get pics of the brake calipers, new tire (cause tires are exciting!) and stainless brake lines next time around.

Still have plenty of miscellaneous stuff left to do including a real good scrub down, but at least it is a (technically) running, titled bike so I guess the $$$ I've spent so far is justified.

More to come......

 

[ron bayless]

I'm loving this thread.

 

[BluePlateSpecial]

I'm thinking the GL master cylinder has to go.

It's made to work with those big cowhorn bars so it really protrudes on the superbike bars. The only reason I tried it is because it only cost me a few $$ for an o-ring. The other one needs a whole new reservoir.

What do you think?

 

[BluePlateSpecial]

Bike now runs and idles great and I was able to ride it around the block but it needs some more tuning to get the carbs dialed in. Brakes are bled. New AGM battery. Still has a couple of bugs in the electrical system but other than that it just about ready to ride. Got a 6000k HID kit with sealed beam conversion and led tail light strip ready to be installed. Aaaaaand here are some more pics......

Coming together nicely-



Freshly painted calipers with stainless steel lines-





Nothing to do with this bike....a vintage bike show in St Pete a few weeks ago since everyone loves pics-



Making some new gaskets for the cases I am polishing-



Finished clutch cover-



Nice and shiny-



2 down, 2 to go-

 

[BluePlateSpecial]

After some fiddling with the carbs to adapt K&N's the bike is now running good throughout the RPM range even under load. Getting used to a big, heavy 90some hp bike coming off of a 27??hp Hondamatic is going to take some time. Needs a couple more tweaks but it is finally road worthy and I will be switching my tag thursday, which is exactly one year from the day I purchased it. Stay tuned.....

 

[BluePlateSpecial]

It has been close to 14 months since I bought this thing but I finally have a road worthy GS to call my own. Still needs some cleaning and tweaking, but at least it is finally rideable.

Mods and repairs to date:

- brakes completely rebuilt with new stainless steel lines swapped master cylinder from parts bike
- polished forks and cases
- new fork seals
- swapped tubeless front wheel from parts bike and installed new front tire
- pounded out dents in front fender
- new turn signals
- 6000k hi-lo HID kit
- LED tail light bulbs
- new AGM battery
- 2006 cbr600rr mosfet R/R
- miscellaneous wiring repairs
- cleaned ignition and turn signal switches
- Plasti-dipped satin black vetter headlight bucket and trim ring
- swapped engine from parts bike
- new valve cover gasket
- new shaft boot
- new K&N pods
- carbs cleaned, rebuilt and rejetted
- fuel tank cleaned
- petcock cleaned and serviced
- new fuel line
- used cables and center stand from parts bike
- new bar end mirrors

Items that still need attention:

- carbs still need to be fine tuned
- diagnose voltage drop
- turn signals and HID's need work (see above)
- rewind stator
- add cell phone mount and charger for GPS
- might switch to euro bars and a smaller master cylinder
- still polishing some of the cases
- tach needs repair or replaced
- fork gaiters I put on are junk and need to be replaced
- paint valve cover
- fix air leak in front tire
- change oil in shaft drive
- clean rattle can paint off of shocks and other bits
- seat is starting to split
- missing one side cover badge
- make custom tank badges, cover with gold leaf and epoxy resin

It's 79 degrees here in FL right now....time to get off the computer and go for a ride!

 

[1948man]

Good work. It gives you a real feeling of accomplishment and you have a bike you can fix if need be.

 

[BluePlateSpecial]

Yes sir.....there have been a few times where I wanted to sell it and buy something that was already in running condition but I'm glad I stuck it out. You really get to know a bike when you learn how to fix it yourself and that can come in handy when you are dealing with something this old.

 

[GSX1000E]

She looks great! I like the fork gaiters too. Now ride it like you stole it!!!